US6774758B2 - Low harmonic rectifier circuit - Google Patents

Low harmonic rectifier circuit Download PDF

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Publication number
US6774758B2
US6774758B2 US10/241,200 US24120002A US6774758B2 US 6774758 B2 US6774758 B2 US 6774758B2 US 24120002 A US24120002 A US 24120002A US 6774758 B2 US6774758 B2 US 6774758B2
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United States
Prior art keywords
inductor
rectifier
inductance
linear
current
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US10/241,200
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US20040046633A1 (en
Inventor
Kalyan P. Gokhale
Alpo K. Vallinmäki
Nicklas Jan Anders Sodo
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ABB Industry Oy
ABB Oy
ABB Inc USA
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Priority to US10/241,200 priority Critical patent/US6774758B2/en
Assigned to ABB INDUSTRY OY reassignment ABB INDUSTRY OY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SODO, NICKLAS JAN ANDERS
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Assigned to ABB OY reassignment ABB OY CORRECTIVE TO CORRECT THE ASSIGNEE'S NAME AND ADDRESS PREVIOUSLY RECORDED AT REEL 013287 FRAME 0347. (ASSIGNMENT OF ASSIGNOR'S INTEREST) Assignors: SODO, NICKLAS JAN ANDERS
Priority to US10/635,313 priority patent/US6922883B2/en
Priority to US10/635,271 priority patent/US6965290B2/en
Priority to AU2003262851A priority patent/AU2003262851A1/en
Priority to CNB03824425XA priority patent/CN100459380C/zh
Priority to EP03795627A priority patent/EP1579555A2/en
Priority to PCT/US2003/026583 priority patent/WO2004025816A2/en
Publication of US20040046633A1 publication Critical patent/US20040046633A1/en
Publication of US6774758B2 publication Critical patent/US6774758B2/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/02—Adaptations of transformers or inductances for specific applications or functions for non-linear operation
    • H01F38/023—Adaptations of transformers or inductances for specific applications or functions for non-linear operation of inductances
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/12—Arrangements for reducing harmonics from ac input or output
    • H02M1/126—Arrangements for reducing harmonics from ac input or output using passive filters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49069—Data storage inductor or core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
    • Y10T29/49078—Laminated

Definitions

  • This invention relates to the input side rectifier in an ac drive system and more particularly to the inductors used therein.
  • the two main subsystems of a modern ac drive system are the input side rectifier system and output inverter system.
  • the purpose of the rectifier system is to convert input ac voltage, from the utility source, into an intermediate dc voltage and the purpose of the inverter system is to convert the intermediate dc voltage into a variable frequency and a variable magnitude ac output voltage.
  • the rectifier systems are also used in equipment such as welding, electroplating and uninterruptible power supplies.
  • the input rectifier system consists of a three-phase diode bridge, either ac or dc side inductor(s) and dc bus capacitors.
  • the three-phase diode bridge converts input ac voltage into dc voltage.
  • the inductor(s) and capacitor(s) serve as a smoothing filter for the intermediate dc voltage.
  • Such a rectifier system when connected to a sinusoidal voltage utility source, draws non-sinusoidal currents. These harmonic currents are not desirable because of their adverse effects (such as energy losses and malfunction of the sensitive equipment) on the utility network. Therefore, it is of commercial importance to reduce the harmonic currents produced by the rectifier systems.
  • the magnitudes of the harmonic currents are mainly dependent on the value of the ac or dc side inductors and on the average value of the load current on the dc side.
  • the level of the harmonic line currents commonly measured in percent total harmonic distortion (%THD) is lower if the value of the inductor is large. But the larger the value of the inductor, the bigger it is in size and the more expensive it is.
  • the %THD increases as the load on the rectifier circuit is reduced from full load to partial load. Since ac drives operate at partial load for most of their operating time, it is important to minimize the %THD of a rectifier circuit at partial load.
  • the present invention reduces the %THD of the line current of a rectifier circuit by incorporating one or more non-linear inductor(s) in the ac or dc side of the rectifier circuits. Specifically, the invention reduces the %THD of the line current at partial loads when compared with rectifier circuits using conventional (linear) inductors. As an additional benefit, the invention also reduces current ripple stress on the filter capacitor at partial loads.
  • a system that has a rectifier having an input for connection to an ac source and an output; and an inductance-capacitance filter connected to the output of the rectifier where the inductance comprises one or more inductors designed to have an inductance that changes non-linearly over a predetermined range of operating current and harmonic currents drawn from said ac source both when a rated load and a partial load are connected to said rectifier that have a percent total harmonic distortion that is less than the percent total harmonic distortion when said inductance comprises one or more linear inductors.
  • a system that has a rectifier having an input for connection to an ac source and an output; one or more inductors designed to have an inductance that changes non-linearly over a predetermined range of operating current and harmonic currents drawn from said ac source both when a rated load and a partial load are connected to said rectifier that have a percent total harmonic distortion that is less than the percent total harmonic distortion when said inductance comprises one or more linear inductors connected between the input of the rectifier and the ac source; and a capacitor connected across the output of the rectifier.
  • a non-linear inductor that has a magnetic material tape wound toroidal core; and an air gap in the core having at least two widths.
  • FIG. 1 shows a schematic for a three phase rectifier system that has a dc side filter inductor.
  • FIG. 2 shows a schematic for a three phase rectifier system that has an ac side filter inductor.
  • FIG. 3 shows the current through the inductor of the rectifier system of FIG. 1 and
  • FIG. 4 shows the line current through phase A of that system with a linear inductor.
  • FIG. 5 shows the current through the inductor of the rectifier system of FIG. 1 and FIG. 6 shows the line current through phase A of that system with a linear inductor and the load on the system at only a predetermined percentage of the rated load.
  • FIG. 7 shows inductance versus operating current curves for the linear and non-linear inductors.
  • FIG. 8 shows the current through the inductor of the rectifier system of FIG. 1 and
  • FIG. 9 shows the line current through phase A of that system with a non-linear inductor.
  • FIG. 10 shows the current through the inductor of the rectifier system of FIG. 1 and FIG. 11 shows the line current through phase A of that system with a non-linear inductor and the load on the system at only a predetermined percentage of the rated load.
  • FIG. 12 shows one of the most commonly used construction techniques used to make a linear dc side inductor.
  • FIG. 13 shows a construction technique for making a non-linear inductor using E and I laminations.
  • FIG. 14 shows another construction technique for making a non-linear inductor using E and I laminations.
  • FIG. 15 shows a construction technique for making a dc side non-linear inductor in the form of a toroidal core.
  • FIG. 16 shows another construction technique for making a dc side non-linear inductor in the form of a toroidal core.
  • FIG. 1 there is shown a three phase rectifier system 10 that has a dc side filter inductor 12 labeled as L.
  • the system has bridge 14 connected directly to the three phases 16 a , 16 b and 16 c of the ac input 16 .
  • Bridge 14 has six diodes D 1 to D 6 .
  • Input phase 16 a is connected to diodes D 1 and D 2 at junction 14 a
  • input phase 16 b is connected to diodes D 3 and D 4 at junction 14 b
  • input phase 16 c is connected to diodes D 5 and D 6 at junction 14 c .
  • Filter inductor 12 is connected between the cathode of each of diodes D 1 , D 3 and D 5 and one terminal of a capacitor 18 , labeled as C, which is in parallel with load 20 represented in FIG. 1 by a resistor labeled Rload.
  • the other terminal of capacitor 18 is connected to the anode of each of diodes D 2 , D 4 and D 6 .
  • FIG. 2 shows a three phase rectifier system 22 in which bridge 14 is connected to the three phases of ac input 16 through three filter inductors 24 a , 24 b and 24 c . Except for the difference in the location of the filter inductors, systems 10 and 22 are otherwise identical and therefore elements in FIG. 2 which have the same function as a corresponding element in FIG. 1 have the same reference numeral that is used in FIG. 1 for that element.
  • FIGS. 3 and 4 there is shown in FIG. 3 the current, IL, through inductor 12 and in FIG. 4 the line current Ia of input phase 16 a for a rectifier circuit that has a linear inductor.
  • the inductance of a linear inductor is substantially constant as a function of the current flowing through it.
  • the circuit component values are as follows:
  • Vin 400V rms at 50 Hz, line-to-line utility voltage
  • Table 1 below shows the harmonic content of the line current Ia in absolute values and as a percentage of the total rms current. The circuit is operating at the rated power level.
  • Table 2 shows the harmonic content of the line current Ia in absolute values and as a percentage of the total rms current.
  • the rectifier circuit is operating at a 33% power level.
  • Replacing the linear inductor by a nonlinear inductor can substantially reduce the harmonic current content of the line current of the rectifier circuit.
  • the nonlinear (also called swinging choke) inductor has a higher value of inductance at lower currents but a lower value of inductance at higher current levels.
  • FIG. 7 shows inductance versus operating current curves for the linear inductor and for the nonlinear inductor where the amount of core material (laminations) and the number of turns of the winding are identical in both inductors. The construction method for the nonlinear inductor is described below.
  • FIGS. 8 and 9 show the inductor current IL and line current Ia of input phase 16 a at rated load, respectively, with a dc side non-linear inductor.
  • FIGS. 10 and 11 show the inductor current IL and line current Ia of input phase 16 a at 33% load, respectively, with a dc side non-linear inductor.
  • Tables 3 and 4, below, show the harmonic current data at rated load and at 33% load respectively.
  • a comparison of the harmonic data from Table 1 and Table 3 shows that when a non-linear inductor is used, the line harmonics at rated current are lower than the harmonic currents produced by the linear inductor.
  • a comparison of harmonic current data from Table 2 and Table 4 shows that at partial load the non-linear inductor produces a substantially lower percentage harmonic currents than the linear inductor.
  • FIG. 12 there is shown the most commonly used construction method to manufacture a linear dc side inductor.
  • This method uses a stack of E and I type magnetic material laminations 30 and 32 , respectively, and a winding 34 around the middle leg 30 c of the E laminations.
  • a constant width air gap g1 is introduced at the middle leg 30 c of the E laminations. It is also possible to introduce an air gap in the two outer legs 30 a , 30 b of the E laminations.
  • An approximate equation for the inductance value L of this type of the inductor is: L ⁇ ⁇ 0 ⁇ N 2 ( g ⁇ ⁇ 1 1 + g ⁇ ⁇ m ⁇ r ) Eq . ⁇ 1
  • N number of turns in the winding.
  • the inductance value is inversely proportional to the width of air gap g1.
  • the value of the inductance is, as is shown in FIG. 7, fairly constant over the intended operating current range.
  • the flux density in the laminations 30 , 32 is below the saturation flux density level and the relative permeability of the lamination material ⁇ r is fairly high.
  • the laminations 30 , 32 start saturating which means ⁇ r of the lamination material starts to rapidly decrease. Therefore, as seen from Eq. 1, inductance value also starts to decrease as shown in FIG. 7 .
  • FIG. 13 shows one of the two construction methods for the non-linear inductor of the present invention.
  • the non-linear inductor of FIG. 13 uses a stack of E and I laminations 40 and 42 , respectively and a winding 44 around the middle leg 40 c of the E lamination 40 .
  • the linear dc side inductor of FIG. 12 has a constant air gap width g1.
  • the air gap of the non-linear inductor of FIG. 13 has a step width g2 (where g2 ⁇ g1) for a portion of the middle leg 40 c of the E lamination 40 .
  • All of the E laminations 40 used in the construction of the non-linear dc side inductor have an identically cut step air gap.
  • the proportion of the width of the middle leg 40 c of the E lamination 40 that produces the smaller air gap g2 with lamination 42 can be varied to achieve the desired non-linearity effect.
  • the inductance versus current curve for the non-linear inductor shown in FIG. 7 was achieved by choosing the width of gap g2 to be equal to 25% of the width of gap g1 and the width of the small air gap g2 was 40% of the width of the middle leg 40 c of the E lamination 40 .
  • the non-linear behavior of the dc side inductor shown in FIG. 13 can be explained as follows. At low operating currents, the ⁇ r of the laminations 40 , 42 is high and the inductance is dominated by the small air gap g2 and therefore the inductance value is high. As the operating current increases, the lamination material below the small air gap starts to saturate and ⁇ r decreases rapidly with the consequent rapid decrease in inductance that is shown in FIG. 7 for the non-linear inductor.
  • FIG. 14 shows the second method to construct the non-linear inductor of the present invention.
  • the middle leg 50 c of some of the E laminations 50 have a constant width air gap g1 with lamination 52 and the middle leg 50 c of the remainder of the E laminations 50 have a different value of constant width air gap g2 (where g2 ⁇ g1) with lamination 52 .
  • the ratio of the number of laminations 50 with a middle leg 50 c that has a small air gap with lamination 52 to those that have a big air gap with lamination 52 can be chosen to achieve the desired non-linear effect.
  • the inductance versus current curve for the non-linear inductor shown in FIG. 7 was achieved by choosing that ratio to be equal to 2:3.
  • the small and big air gap laminations can be placed in different positions relative to each other. In the non-linear inductor of FIG. 14 they are shown with those laminations of the middle leg 50 c that produces the smaller air gap with laminations 52 in the center of the entire stack. Another option is to reverse the arrangement where the big air gap laminations are in the center of the stack. Some other arrangements are: side-by-side positioning of small and big air gap laminations or dispersing small and big air gap laminations uniformly throughout the stack of E laminations 50 .
  • an air gap having the characteristics described above for the embodiments of FIGS. 13 and 14 may also be at either of both of end legs 40 a and 40 b for the embodiment of FIG. 13 and at either or both of end legs 50 a and 50 b for the embodiment of FIG. 14;
  • the non-linear inductor in both figures may also be embodied using for example only E laminations or using U shaped laminations and I laminations or using only U shaped laminations or any other shape or combination of shapes of laminations that allow for one or more gaps that have the characteristics described above for the embodiments of FIGS. 13 and 14.
  • FIG. 15 shows a construction method for a dc side non-linear inductor in the form of a toroidal core 60 .
  • a tape of a magnetic material is wound in a toroidal shape.
  • An air gap 62 is introduced by cutting core 60 in an axial direction.
  • the larger air gap g1 is placed on the outer edge of the toroidal core 60 and smaller air gap g2 is placed in the middle of the toroidal core 60 .
  • the construction of FIG. 15 is the toroidal equivalent of the stepped gap E-I construction of FIG. 13 .
  • FIG. 16 shows a construction method for a dc side non-linear inductor in the form of a toroidal core 70 which as is described below has an air gap that is different in construction than the air gap of toroidal core 60 of FIG. 15 .
  • core 70 a tape of a magnetic material is wound in a toroidal shape.
  • An air gap 72 is introduced by cutting core 70 in a radial direction.
  • the tape or “laminations” on the outside (diameter) of the toroidal core 70 have a bigger air gap (g1) than the air gap (g2) in the tape or “laminations” which are inside (diameter) the toroidal core 70 .
  • the construction of FIG. 16 is the toroidal equivalent of the variable gap E-I construction of FIG. 14 .

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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  • Physics & Mathematics (AREA)
  • Nonlinear Science (AREA)
  • Rectifiers (AREA)
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US10/241,200 2002-09-11 2002-09-11 Low harmonic rectifier circuit Expired - Lifetime US6774758B2 (en)

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Application Number Priority Date Filing Date Title
US10/241,200 US6774758B2 (en) 2002-09-11 2002-09-11 Low harmonic rectifier circuit
US10/635,271 US6965290B2 (en) 2002-09-11 2003-08-06 Low harmonic rectifier circuit
US10/635,313 US6922883B2 (en) 2002-09-11 2003-08-06 Method for making a non-linear inductor
PCT/US2003/026583 WO2004025816A2 (en) 2002-09-11 2003-08-26 Low harmonic rectifier circuit
AU2003262851A AU2003262851A1 (en) 2002-09-11 2003-08-26 Low harmonic rectifier circuit
CNB03824425XA CN100459380C (zh) 2002-09-11 2003-08-26 低谐波整流电路
EP03795627A EP1579555A2 (en) 2002-09-11 2003-08-26 Low harmonic rectifier circuit

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US10/635,271 Division US6965290B2 (en) 2002-09-11 2003-08-06 Low harmonic rectifier circuit

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US20110035607A1 (en) * 2009-08-10 2011-02-10 Alexandr Ikriannikov Coupled Inductor With Improved Leakage Inductance Control
US20110032068A1 (en) * 2009-08-10 2011-02-10 Alexandr Ikriannikov Coupled Inductor With Improved Leakage Inductance Control
US7893806B1 (en) 2002-12-13 2011-02-22 Volterra Semiconductor Corporation Method for making magnetic components with N-phase coupling, and related inductor structures
US7898379B1 (en) 2002-12-13 2011-03-01 Volterra Semiconductor Corporation Method for making magnetic components with N-phase coupling, and related inductor structures
US20110148560A1 (en) * 2009-12-21 2011-06-23 Alexandr Ikriannikov Two-Phase Coupled Inductors Which Promote Improved Printed Circuit Board Layout
US7994888B2 (en) 2009-12-21 2011-08-09 Volterra Semiconductor Corporation Multi-turn inductors
US20140055226A1 (en) * 2012-08-21 2014-02-27 Cyntec Co., Ltd. Variable coupled inductor
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US8975995B1 (en) 2012-08-29 2015-03-10 Volterra Semiconductor Corporation Coupled inductors with leakage plates, and associated systems and methods
US9019063B2 (en) 2009-08-10 2015-04-28 Volterra Semiconductor Corporation Coupled inductor with improved leakage inductance control
US9093212B1 (en) * 2012-05-01 2015-07-28 Universal Lighting Technologies, Inc. Stacked step gap core devices and methods
US9401653B2 (en) * 2014-09-04 2016-07-26 Bose Corporation Power supply with switching converter
US10191859B2 (en) 2016-03-31 2019-01-29 Apple Inc. Memory access protection apparatus and methods for memory mapped access between independently operable processors
US10256025B2 (en) 2015-07-10 2019-04-09 Pulse Electronics, Inc. Step gap inductor apparatus and methods
US11361897B2 (en) * 2018-03-21 2022-06-14 Eaton Intelligent Power Limited Integrated multi-phase non-coupled power inductor and fabrication methods
US11398333B2 (en) * 2020-04-15 2022-07-26 Monolithic Power Systems, Inc. Inductors with multipart magnetic cores
US11682515B2 (en) * 2020-04-15 2023-06-20 Monolithic Power Systems, Inc. Inductors with magnetic core parts of different materials

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US6774758B2 (en) 2002-09-11 2004-08-10 Kalyan P. Gokhale Low harmonic rectifier circuit
US20050162021A1 (en) * 2004-01-26 2005-07-28 Dell Products L.P. Information handling system including zero voltage switching power supply
DE102004031944A1 (de) * 2004-06-30 2006-01-19 Deutsche Thomson-Brandt Gmbh Stromversorgung für eine Metalldampflampe
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EP2674950A1 (en) 2012-06-11 2013-12-18 Tyco Electronics Nederland B.V. Contactless connector, contactless connector system, and a manufacturing method for the contactless connector
CN103578691B (zh) * 2012-07-26 2016-08-17 浙江海利普电子科技有限公司 扼流圈和emi滤波电路
CN104851576A (zh) * 2014-02-17 2015-08-19 伊顿公司 一种电感线圈及电磁器件
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WO2004025816A2 (en) 2004-03-25
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US6922883B2 (en) 2005-08-02
AU2003262851A1 (en) 2004-04-30

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